ISSUE 02 | 2010
the customer magazine from meypack
Trendsetterfor ice cream MEypack rEportagE aboUt MIko, a FrEnch coMpany
bElongIng to thE UnIlEvEr groUp
Finest Franconian quality MEypack MachInE packS prEMIUM wInES For thE gwF
Delectable coffee kraFt FoodS UkraIna pUtS ItS
trUSt In MEypack tEchnology
Meypack shows its colours nEw coloUr codEd SyStEM For MEypack’S MachInE SErIES
EditorialDear Readers, Two trade fairs – the FachPack and the Brau Beviale – are on Meypack’s
agenda this year. Signs of the interpack 2011 can already be detected and numerous international trade fairs, such as the Emballage in France, the Pack Expo in Chicago and the Upakovka in Russia are beckoning with continuously new opportunities to come together with our customers. The question increasingly arises – not only in economically challenging times – whether trade fair participation makes sense, particularly from the backdrop of the cost-benefit perspective.
Particularly in our line of business – one of machines that are sophisti-cated and require detailed explanations – it is still important to physically come together, despite the improved communication offered by the internet and an increasingly village-like world. It is crucial for us to understand our customers and their needs and to convey and prove that Meypack not only understands their objectives but can also help to achieve them. It involves more than just staying in touch with one’s contacts. It is the personal relation-ship management that pays off at the end of the day. This is a business aspect where somewhat smaller organisations, who as a rule know their customers and their markets very well, can score extra points. During the trade fairs over the past years, this is something that has become very clear.
The forward march of internationalisation forces every medium-sized
company to decide which of the countless worldwide trade fairs warrant direct participation. Trade fair participation, particularly in Asia, Russia and in Arabian countries, currently provide fine opportunities for growth in machine manufacturing. Especially in these far-away regions, trade fairs offer excellent opportunities to meet with business partners, representatives, customers and interested parties. A great deal will happen in these markets in the years to come.
In this issue of the kompackt, we not only report on Meypack’s current trade fair activities, but we also have once again a large number of exciting projects that we would like to introduce to you. Among those projects are new packaging machines for Kraft Foods Ukraina, Miko and Carlsberg Sverige.
I hope you enjoy this new kompackt and I wish you and us all a successful autumn of trade fairs.
gernot keßeldirector of Sales (germany, austria,Switzerland) and technical director
02 | 2010
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02 Editorial
04 France: Trendsetter for ice cream reportage about Miko, a company in the Unilever group Interview with project Manager christophe lecoutey
10 1:0 Carlsberg carlsberg Sverige, the market leader for beer in Sweden, packs with a Meypack vp 521
12 Finest Franconian quality Meypack packs premium wines for the gwF
14 Sealed pouches & Doypacks Meypack vp 453 packs 4-sealed-edge pouches and doypacks in display trays with lids
16 Simply delicious kraft Foods Ukraina chooses Meypack technology
20 The nation’s darlings bEwItal petfood closes bags of pet food with a Meypack cbS-w 600
22 Meypack shows its colours Introduction of the new colour coded system for Meypack’s machine series
23 Last but not least
Imprint
Meypack verpackungssystemtechnik gmbhIndustriestraße 3d-48301 nottuln-appelhülsentel.: +49 (0) 2509 - 940Fax: +49 (0) 2509 - [email protected]
conception, compilation, design: www.fbkb.comphotos: Meypack verpackungssystemtechnik gmbh,Miko/Unilever, carlsberg Sverige, gwF, kraft Foods Ukraina,bEwItal petfood, istockphoto.com print-run: 3,000 copiesFrequency: 2 x per year
I n 1921, the Spaniard Luis Ortiz founded Miko in Saint-Dizier, France. As the head of this small, family-run operation, Luis
Ortiz produced and sold ice cream and hot chest-nuts at weekly markets, in city parks as well as at local celebrations. In the second generation, the business was expanded by Ortiz’s two sons and under this new management, the company grew continuously.
The company was eventually renamed in 1951. The name “Miko,” under which the company has since been known, stands for the two main ingredients of the ice cream produced – milk and chocolate.
In 1954, Miko switched over to industrial ice cream production, and as a multinational company, it was soon serving a large number of foreign markets. The company has remained an internationally active enterprise to this day.
In 1994, the company was acquired by the Dutch-British Unilever Group but is still active in France under its original name “Miko.” Unilever, with its headquarters in Rotterdam and in London, is one of the largest producers of consumer goods world-wide. The main areas of business encompass food, cosmetics and body care as well as household and
textile care products. Unilever employs around 180,000 people in over 100 countries around the world.
a hEart For IcE crEaM: UnIlEvEr’S natIonal brand StratEgy
Unilever ice cream is sold in Germany under the brand name “Langnese;” in Austria, under
“Eskimo;” in Switzerland, under “Lusso” and in Great Britain, under “Wall’s,” just to name a few country-specific examples. In order to take advantage of the strong brand-recognition enjoy-ed by the brands prior to their acquisition by Uni-lever, the brand names were retained. However, an affiliating brand-recognition feature for all brands was created: a standard logo in the form of a heart, the so-called “Heartbrand.” These “Heartbrand” brands are sold in over 40 countries and are now so well-known
thE MarkEt For IcE crEaM IS booMIng. nEw trEndS SUchaS dIEtary prodUctS, organIc IcE crEaM and hEalthy FrUItaddItIvES wIll EnSUrE that thIS contInUES to bE thE caSEIn thE nEar FUtUrE. thIS SItUatIon IS oF bEnEFIt to MIko, acoMpany bElongIng to thE UnIlEvEr groUp and onE oF thEMoSt SUccESSFUl IcE crEaM prodUcErS In thE world.
Milk & Chocolate
lactose-free. Even soy ice cream and low-carbo-hydrate ice creams are offered.
MIko – actIvE worldwIdE bUt alwayS loyal to ItS rootS
Even though Miko, the largest ice cream producer in the Unilever Group, now supplies all international markets with ice cream and thus produces the most well-known brands in the Unilever portfolio, the company has always remained true to its roots. The headquarters and the main production facility are still located in the small city of Saint-Dizier in north-eastern France, in the Champagne-Ardenne region. The city of 30,000 residents is situated on the Marne River, which flows into the Marne-Saône-Canal. Through the additional utilisation of other rivers and canals, this provides a navigable route from the area around Paris all the way to the Mediter-
that one almost automatically associates ice cream with the large red heart. Meanwhile, all ice cream products that carry this logo have become classics.
coMMItMEnt to hEalthy nUtrItIon – For IcE crEaM, too
With its own internal corporate programme for healthy nutrition, Unilever has been conduct-ing research worldwide since 2003 to create new recipes for healthy, balanced products. This is also related to a global paradigm shift in the kinds of food people are eating. Food products are no longer seen purely as basic foods or deli-cacies, but rather they should have a positive influence on people’s health. Therefore, from the start, the nutritionists have placed a high priority on avoiding fat and sugar. For example, between 2005 and 2008, 37,000 fewer tonnes of sugar and 45,000 fewer tonnes of fat were used in production.
Even in the case of ice cream – a product typi-cally high in fat and sugar content – the use of these ingredients has been reduced. Already, every “Heartbrand” ice cream product is being offered in a “light” version – with significantly less fat and sugar and subsequently fewer calories. Furthermore, an increasing number of products are being offered in snack-sizes to help people control their portion sizes more easily.
In addition to lower-fat and lower-sugar con-tent ice creams, Miko also offers special products, such as those suitable for diabetics. There are ice cream products that contain no sugar or are
Aiming high: Four-laned infeed, separation and stacking of ice cream containers
Miko is one of the numerous successful ice cream producers
belonging to the worldwide active Unilever Group. The
company was founded by Luis Ortiz in the French city of
Saint-Dizier in 1921. In 1994, Miko was acquired by Unilever, the Dutch-British multinational. Langnese, Eskimo and Lusso are
just a few of the top interna-tional brands belonging to
Unilever. They can be identified by the “Heartbrand” logo.
ranean Sea. The largest man-made lake in France, Lake Der-Chantecoq, is located approximately ten kilometres west of the city.
The region of Champagne-Ardenne is named after the historical landscape of the Cham-pagne region and the Ardennes Moun-tains. It encompasses an area of 25,600 km2 and has 1.35 million inhabitants. It borders Belgium in the North, the Lorraine and Franche-Comté regions in the East, Burgundy in the South and the Île-de-France and Picardie regions in the West.
hIgh-tEch For a dElIcacy
Miko selected an end-packaging machine from Meypack to pack its containers of ice cream. In February 2010, commissioning was carried out on a highly flexible, combined end-packaging machine that packs containers of ice cream in various pack sizes and formations into wrap-around cases or, after a brief changeover, just in film. The machine consists of two machine units that are installed one after the other and have a common control system. These two machines are the VP 501 continuous motion case packer and the SW 60-30 shrink wrapper.
The products enter the end-packaging section in four lanes and are then separated so that two streams of products – one on the left side and one on the right side – flow into a stacking station One after the other: Continuous grouping of stacked ice cream containers – without any format parts
located in front of the machine. In each lane, the containers of ice cream are stacked in two’s or three’s and subsequently brought together on the inflow conveyor where they are transferred to
the grouping section. Depending upon the format selected, the corresponding
product formations are created and – in the case of the wrap-around application – transported
onto the cardboard blank, which is then folded around the product and
sealed. For this type of packaging, the packed products simply pass through
the downstream Meypack shrink wrapper without being packed in film.
When the containers of ice cream are not packed in cases but rather just in shrink film, the wrap-around packaging module is deactivated. When this is carried out, all of the components used to produce wrap-around cases are set so
Interview
that they are no longer in the working area of the machine. After that, an additional transport con-veyor is raised up into the vacated working area of the machine. In order to shorten this change-over procedure, the adjustment is motor-driven. This transport conveyor now takes over the entire product transport from the product grouping area up to the shrink wrapper.
If the customer desires, two different films can be used in the packing process. To increase the slip-resistance of the packs during future transport, a textured film is affixed to the bottom of the pack. The top film is smooth and white-faced. This makes the packs particularly suitable to be designed for effective marketing purposes and printed with information for the consumer during the follow-ing production stages. After both films have been wrapped around the pack, they are joined with Meypack’s proven cut and seal technology.
The film magazines are equipped with fully-automatic film roll change units,
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allowing film changes to be carried out during running production and at full production speed, without any interruption in production.
This packaging machine is already the second machine Meypack has supplied to Miko in Saint-Dizier. Back in 2008, an SW 60-30 shrink wrapper was delivered to pack containers of ice cream in film. This machine was also equipped to handle different pack sizes and formats as well as being outfitted with a stacking station for products and an automatic film roll change unit. Meanwhile, a third Meypack machine has been ordered. This time it is a VP 451 wrap-around case packer.
IntErvIEw wIth chrIStophE lEcoUtEy, projEct ManagEr at MIko In SaInt-dIzIEr, FrancE
Mr Lecoutey, which Unilever brandsof ice cream are produced in yourproduction facility?
At our production facility in Saint-Dizier, we produce the ice cream brands Carte d´Or, Cremissimo, Cornetto, Hertog and Calippo.
Does Miko produce solely for thedomestic market or do you also export?If yes, where to?
We are a European factory. Among the most important countries into which we export are Germany, Great Britain and Italy.
How would you describe the consump-tion of ice cream in France? How muchice cream per capita is consumed annually? And what are the most popular flavours?
The consumption of ice cream in France primarily takes place at home, particularly during celebrations. On average, people in France consume around 6 litres of ice cream per year. The most popular flavours accord-ing to production quantities and turnover figures are vanilla, chocolate and coffee.
A further VP 451 case packer will bejoining the existing Meypack machines.That is a very positive development forMeypack in its cooperation with yourcompany. How did the contact to Mey-pack emerge and what were the criticalfactors at work in the decision to worktogether with Meypack?
There were a number of reasons why Miko once again chose Meypack while we were planning to purchase a VP 451 case packer. The first reason was the trust that we have in Meypack. Two machines already serve as reliable components in our machine park. A further explana-tion can be found in the design of the machines: Meypack machines are easy to operate, are clearly structured and above all, they are accessible. Finally, the high degree of reliability played a definitive role in Miko’s decision to purchase an-other Meypack machine. And of course, we decided to buy yet another Meypack machine in order to achieve uniform end-packaging in our facility.
You pack ice cream products inwrap-around cases and in film. How important was the issue of machine flexibility to you? How important is packaging variety today?
For this project, the issue of machine flexibility was extremely important. At the beginning of the project, we were still planning to have two machines, one for film packaging and one for case packing. The solution to have one machine handling both packaging variations was therefore simply an enormous advantage. It was also much easier to plan where to install one machine in the production hall rather than two. Both packaging styles are important to us since we have to be able to fulfil our
customers’ wishes. For example, while the German market requires our ice cream to be transported in cases, we deliver ice cream to other European country-specific markets in film end-packaging.
People are paying more attention totheir health these days. What influence has this change in consciousness had on consumer behaviour – in particularwith respect to treats such as ice cream?
These days, our product development department most certainly takes con-sumers’ heightened health-consciousness into consideration. As a result, we do not use any food colourings or artificial aromas.
What trends do you envision in the ice cream market? And what conse-quences will arise for you because of this in the upcoming years?
The trend is heading toward diversifi-cation. That means that we provide con-sumers with the choice of many different and varied flavours. In particular, the creation of new ice cream products and flavour variations is exciting for custom-ers and prompts them to try and discover new ice cream products.
Mr Lecoutey, thank you very much for speaking with us today.
Meypack representative Sweden:
advanced packaging nordeuropa abpeppargränd 1113536 tyresöSweden
tel.: +46 (0) 8 - 6496994Fax: +46 (0) 8 - 6491170
contact person: bart ten napel
Carlsberg Sverige is the market leader for beer in Sweden; it pro-duces and/or sells respectively, in addition to the Carlsberg,
Falcon and Pripps Blå brands, the well-known premium mineral water Ramlösa and Pepsi-Cola in coopera-tion. In 2006, the Danish premium beer Jacobsen – one of the most expensive beers in the world – came
onto the Swedish market.
Today, Carlsberg is one of the most widely sold brands of beer in the world. The green lettering with the stylized hops and the English slogan that it is “Probably the best beer in the world” have remained relatively unchanged since the 1970’s. Carlsberg is also very active in sponsoring sporting events and also lending its name to cultural facilities.
100 % carlSbErg. 100 % Football.
Just like the entire Carlsberg Group, Carls-berg Sverige is also very active in sponsoring sporting events and it supports a wide range of local football clubs. Living up to its motto “100 % Carlsberg. 100 % football.” the Carlsberg Group not only sponsors FC Liverpool and the Danish clubs FC København and Odense BK, but it was also active during the past world football cham-pionship – with raffles, give-aways, a “fan-jersey” shop and its own fan club on the popular internet platform Facebook.
rapId growth dEMandS thE hIghESt lEvEl oF pErForMancE and rElIabIlIty
In the spring of 2010, a Meypack VP 521 high-speed case packer was delivered and integrated into an existing bottling line to pack glass bottles into trays and wrap-around cases. The machine was delivered together with a transport system for bottles and packs and then commissioned. The bottles being packed contain beer and mixed drinks and range in size between 0.28 litres and 0.50 litres.
The bottles enter the Meypack machine in multiple lanes, and depend-ing upon the desired format, they are divided into the machine’s lanes, then grouped and are currently being packed into wrap-around cases. The machine is designed to also pack into trays.
One special request expressed by the customer was to have flexible and above all automatic speed adjustment of the packaging machine to match the actual output of the filler. The machine was pro-grammed in such a way that when the filler oper-ates at a slower speed, the speed of the packaging
machine slows down accordingly (or in the event of increased output, it speeds up). The result: “stop and go” machine movement can be avoided. Conse-quently, the noise level is significantly reduced and the products are handled much more gently.
The Meypack case packer is also equipped with automatic adjustment points. This allows the format changeover times to be shortened considerably.
This VP 521 is the third machine that Meypack has supplied to the Group worldwide and a fourth will follow for the Carlsberg brewery Saku in Estonia.
The international Carlsberg Group, with its headquarters in the Danish capital of Copenhagen, is the fourth largest
brewery corporation in the world behind Anheu-ser-Busch InBev, SABMiller and Heineken. In 2008, the group sold more than 120 million hectolitres of beer – that makes 100 million bottles of beer per day. In German-speaking areas, Carlsberg is well represented by the brands Holsten, Astra, Lübzer, Feldschlösschen, Duckstein and Hannen Alt, to name a few.
Carlsberg’s Swedish operations have their head-quarters in Stockholm. Carlsberg Sverige operates two production facilities – a brewery in Falken-berg producing beer and soft drinks and a mineral water bottling plant in Ramlösa. The company was created through the takeover of the Pripps Brewery in 2001 as well as the Falcon Brewery in 1996. Up until the takeover, Pripps had been known as the largest brewer of beer in Sweden and it produced the top-seller “Pripps Blå,” a popular lager beer. Carlsberg’s cooperation with the Falcon Brewery began years before the actual takeover. The Falcon Brewery had been producing Carlsberg beer under license since the mid 1980’s.
carlSbErg SvErIgE IS thE MarkEt lEadEr For bEEr In SwEdEn. that IS cErtaInly nothIng to bE takEn For grantEd whEn conSIdErIng thE dIScErnIng SwEdISh bEEr MarkEt. thE hIgh bEEr tax StIMUlatES prIvatE IMportatIon oF bEEr and thUS placES EvEn hIghEr dEMandS For FIrSt claSS prodUctS In ordEr to MaIntaIn StablE doMEStIc tUrnovEr. thE potEntIal IS MoSt cErtaInly thErE: wIth a pEr capItal conSUMptIon oF aroUnd 54 lItrES pEr yEar, SwEdEn FIndS ItSElF In thE UppEr MId-rangE worldwIdE – and thE tEndEncy IS IncrEaSIng.
Carlsberg Sverige is the market leader for beer in Sweden. Approximately
1,100 employees work for the company at its headquarters in Stockholm, in the brewery in Falkenberg as well as at the mineral water bottling plant
in Ramlösa. Carlsberg Sverige enjoys a market share for beer
of nearly 36 %.
1:0 Carlsberg
Everything in sync: bottles of carlsberg beer exit the Meypack vp 521 in stable wrap-around cases
Finest Franconian qualitythE wInzErgEMEInSchaFt FrankEn Eg (gwF), FoUndEd In 1959, IS thE MoSt IMportant prodUcEr oF FranconIan wInE and onE oF thE lEadIng wInE growErS’ aSSocIatIonS In gErMany. approxIMatEly 2,600 SElF-EMployEd wInE-growErS cUltIvatE 1,500 hEctarES oF vInEyardS In thE wInE rEgIonS oF FranconIa and taUbErFrankEn. to pack thEIr glaSS bottlES FIllEd wIth ExqUISItE wInES, thE gwF wInEMakErS choSE an End-packagIng SolUtIon FroM MEypack.
The GWF is at home in the entire area of Franconia and Tauberfranken in north-western Bavaria, from Spessart to Steiger-
wald and from the Saale Valley to Tauberfranken. In 1959, around 2,600 winemakers joined forces and established the GWF. Since then, they have been pursuing their common objectives of perfecting their craftsmanship, upholding their sense of tra-dition and maintaining a high level of innovation. The GWF consistently lives its philosophy that good wine cannot be “made” but rather has to grow in the vineyards. And this unique quality must be maintained until the wine reaches the bottle and ultimately the transport case, without compromise.
bESt qUalIty – alSo a gIFt oF natUrE
Even with the gentlest processing, wine can only be as good as the soil of the vineyard where
the grapes are grown. Rich in minerals and nutrients, the soil of this region lends unmis-takable flavour to its wine. The wide variety of Franconian wines can be attributed to the diverse geology of the area around the Main River. The ground, in which the vines spread their roots, be it new red sandstone, shell limestone or keuper, plays a very large role in determining the taste of the wine. Among the most well-known grape varieties harvested are Müller-Thurgau, Silvaner, Bacchus, Grauer Burgunder, Domina, Schwarz-riesling and Regent.
thE bockSbEUtEl – thE SyMbol oF FranconIan wInE
For over 250 years, the Bocksbeutel has been the typical vessel in which Franconian wine has been sold. Originally, the Bocksbeutel was filled with the most revered and best wine, the
Würzburger Stein, and later also with other fine wines from the Franconian region. This attribute has remained until today:
the Bocksbeutel still stands for high quality wines from the Franconian region.
The curvaceous bottle form resem-bles a flattened ellipsoid; the volume is typically 0.75 litre. This tradi-
tional bottle form for Franconian wines was likely derived from
canteens, which were flattened for practical purposes so that they could be more easily carried in a pack or directly on the body. Furthermore, the bottle would not roll away if placed on uneven or sloped terrain. The origin of the name “Bocksbeutel” is controversial. It is generally assumed that due to its similar shape, the term Bocksbeutel is derived from the scrotum (Beutel) of a billy-goat (Ziegenbock). Sacks (Beu-tel) of this type were previously used to trans-port fluids. Another interpretation purports that the term has its origins in the Low German word “Buchbeutel.” Since pre-Reformation times, this “Booksbüdel” has been a sack-like covering for prayer and song books.
The Winzergemeinschaft Franken has been using this traditional bottle form and filling half of its wine in Bocksbeutel for over 50 years. With that, the GWF is the world’s largest Bocksbeutel producer and seller. The Bocksbeutel indicates the high quality wine in the bottle, attracts atten-tion and sets itself apart from the other bottles of wine at the point of sale.
gEntly packIng SElEct wInE
Meypack installed a tray and wrap-around case packer with a downstream continuous motion lid station in Kitzingen. The VP 512 machine is designed to process 250 ml and 750 ml Bocksbeutel bottles as well as 750 ml and 1,000 ml bottles of Bordeaux wine. Packing is carried out in trays, wrap-around cases and trays with externally sealed U-lids.
A central requirement for this machine was the high adaptability to a variety of formats. Currently, the Bocksbeutel are being packed in wrap-around cases of 6 or 24 bottles as well as in a single row format of 5 or 6 bottles in trays with lids. The end-packaging of the Bordeaux bottles is currently being done in 6-bottle wrap-around cases.
All bottles are transferred to the packaging machine in the appropriate number of lanes via
Founded in 1959, the Winzer-gemeinschaft Franken eG
(GWF) is the most important Franconian wine producer. About 2,600 self-employed winemakers cultivate 1,500 hectares of vineyards in the wine areas of Franconia and
Tauberfranken. Among the most well-known grape varieties grown are Müller-Thurgau, Silvaner, Bacchus, Grauer
Burgunder, Domina, Schwarz-riesling and Regent.
a lane dividing system, although the transfer of the Bocksbeutel takes place with the short side leading. The arrangement of the Bocksbeutel inside the case is both short and long side lead-ing. Turning the Bocksbeutel at the neck of the bottle from short to long side leading, depend-ing upon the required configuration inside the case, is easily handled by a turning station installed on the infeed conveyor. After that, the grouping, the positioning of the bottles on the blank and the final sealing of the cases are car-ried out before the cases exit the machine long side leading.
During the tray with lid application, the Bocks-beutel are packed in a tray and enclosed with a U-lid applied and glued on the outside of both nar-row sides of the tray. The finished trays with lids exit the machine short side leading, as opposed to the wrap-around cases’ long side leading exit.
To save space, the switch cabinet is mounted on the machine. The machine is operated from a touch screen operator panel installed on the machine.
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Sealed-edge pouches & Doypacks –efficiently packed with Meypack technology
thE MEypack vp 453 packS 4-SEalEd-EdgE poUchES and doypackS In dISplay trayS wIth lIdS and dEMonStratES thErEby ItS SolId rElIabIlIty
poUch packagIng – a tEchnIcal challEngE For End-packagIng
The challenge of packing pouches lies in the “instability” of the product – especially in the case of the double chamber pouches. The pouch mate-rial used is not firm, resulting in pouches without defined, recurring dimensions, thus making han-
D oypacks and 4-sealed-edge pouches are packed on Meypack’s VP 453 in display
trays with lids partially inserted and partially applied to the outside of the trays. On the long side of the tray, the lid is partially inserted into the tray and secured with adhesive points against slippage. The “lid securing technique” is a modern packaging solution, ensuring stability of the packaging as well as enabling quick and easy opening of the end-packaging at the point of sale. The lid is reliably secured with two adhesive points, yet easy to open manually.
The Meypack machine can process the most diverse formats that are dependent upon the respective pouch sizes. In this case, the pouches are always packed into the trays in single rows. Both width and height play a role as does the thickness, which is dependent on the filling. In addition, the Meypack machine is also able to process the so-called double chamber pouch. The changeover to different tray formats takes place nearly tool-free; only product specific parts need to be exchanged.
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perfect fit: lid forming station with lid waiting to be suctioned into the forming tool
dling a challenge. In contrast to tin cans or glass jars, the different contents can have an impact on the shape of the pouches to be packed and how the pouches move throughout the packaging process.
Before the 4-sealed-edge pouches and Doy-packs can be packed in the trays, they pass over a vibrating conveyor. On this vibrating convey-or, the contents of the pouches are distributed as evenly as possible and then weighed exactly. The pouches are then divided onto two separate conveyors and fed onto the two infeed conveyors of the VP 453. From there, the pouches enter their respective stacking shafts, in which the products are continuously stacked horizontally. The products rest on retractable latches that move downwards into their respective pivoting cassettes. Meanwhile, stacking continues in the upper portion of the stacking shaft. Once the defined number of pouches has been reached, the cassette pivots 90 degrees and moves back to the top. During this process, the stacking continues, thereby fulfilling the requirements for the contin-uous packing principle.
The product formations are then alternately pushed out of the respective cassettes on the left and right sides by a cross-pusher onto the tray blank in such a way that no pouch can fall down. During the lowering process as well, the product formations are always held securely in place. The tray is glued and pressed in the index chain. During the next step, the finished tray is trans-ported upwards once again into the lid station.
This is where the lid is placed on the tray. Guides on both sides ensure that the middle part of the lid is inserted into the tray before the flaps are folded, glued and pressed. At the next station in the machine, the adhesive points that secure the lid against slippage are applied. For this purpose, two spreading forks push the inserted part of the lid to the inside. These adhesive points are briefly pressed on pneumatically. Finally, the finished tray with lid is transported out of the packaging machine.
thE SEalEd-EdgE poUch – a popUlar packagIng StylE For thE conSUMEr
The sealed-edge pouch is an attractive solu-tion for the consumer since it is not only easy to handle and space-saving to store, but above all it also guarantees hygienically safe food packaging. In particular, powdery products like instant soups in pouches and liquid products (e.g. beverages, syrup) are packed safely and in a space-saving manner. The sealed-edge pouch is available in different varieties. There are stand-up pouches, those without a flat bottom and those that are re-sealable.
The 4-sealed-edge pouch is produced from film on a roll. After the edges have been sealed and the pouches have been filled, the sealed-edge pouch is then sealed at the top. The airtight seal is usually created thermally but is occasionally created by ultrasound.
The most common types of sealed-edge pouches are flat pouches, the standing pouches, double pouches and folded bottom pouches.
all together: pivoting stacking cassette moves the pouches directly onto the tray blank
reliably secured: lid flaps are folded, glued and pressed on, and receive extra adhesive to secure the lid
The Meypack VP 453 packs 4-sealed-edge pouches and Doypacks in display trays
with lids partially inserted and partially applied to the outside of the trays. The lid flap is only inserted into the long side of the
tray and is secured with adhesive points to prevent possible slip-
page. This is a modern packaging solution, ensuring stability of
the packaging as well as enabling quick and easy opening of the end-packaging at the point of
sale. The Meypack VP 453 pro-cesses the most diverse formats, which are dependent upon the pouch sizes being processed.
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The goals of these efforts in-clude the reduc-tion of energy and water wastage, the prevention of unnecessary transport and in particular, the avoidance of using unnecessary packaging. The packaging represents the first yet also the last “experience” the customer has with any producer’s goods. Even for this reason alone, the packaging plays a central marketing role as a marketing instru-
ment for branded products and can therefore not be reduced to having merely a transport function. Despite this, Kraft Foods decided to reduce its packaging material by approxi-
mately 150 million pounds by 2011 – and that along the entire value added production chain. One of the means of achieving this objective is to leave off unnecessary packaging sections, while another is to develop new, more efficient packaging designs. In order to create the most optimal packaging design, Kraft Foods develop-ed the “Packaging-Eco-Calculator,” a tool to create packaging that requires the least material possible. In addition to the aspect of the amount of packaging used, the topic of packaging mate-rial origin is increasingly taking more of the centre stage in people’s interests. This is another
1989 and the company names changed to Kraft General Foods. The businesses of Jacobs coffee and Suchard chocolate merged in 1982 and then were acquired by Kraft General Foods in 1990. In 1995, the company’s name was changed to Kraft Foods. The subsequent growth of the corporation was aided by acquisitions of well-known brands such as TERRY’S chocolate and the Scandinavian chocolate brands FREIA and MARABOU. One of the most recent, large acquisitions was the multi-billion dollar takeover of the Nabisco Holdings Corporation.
In 2007, Kraft Foods was success-fully brought as a spin-off onto the stock market by the Philip Morris Corporation, since re-named Altria Group Inc., and is an in-dependent public corporation. The first acquisi-tion of the new corporation was the purchase of the entire biscuit business of the Danone Group
– among those the popular brand LU.
coMMIttEd to SUStaInabIlIty: kraFt FoodS placES thE prESErvatIon oF lIMItEd rESoUrcES hIgh on ItS lISt oF prIorItIES
Through the program “Better World,” Kraft Foods has been conducting a large number of acti-vities for the purpose of protecting the environ-ment as well as its own employees and customers.
The company history of Kraft Foods stretches as far back as 1895 and has consistently been marked by numerous acquisitions of entire companies and by the integration of purchased brand name prod-ucts into its own company portfolio. Some of the company’s first well-known brands that are still gracing the supermarket shelves today are the quality chocolate brands BAKER’S and Côte d’Or as well as the Maxwell House brand of cof-fee. Created back at the end of the 19th Century, the German coffee brand JACOBS was integrated into the corporation in 1990 through the acqui-sition of the Jacobs Suchard Group. In the years leading up to the middle of the 20th Century, a great number of brand products were devel-oped and marketed. It was the era of the great brands for daily consumption. Product brands such as MILKA, TOBLERONE and MIRACLE WHIP are still holding their own today and have enjoyed extraordinarily long product life cycles
that are more of a rarity in today’s modern marketing landscape.
The company’s business start-ed under the name General
Foods in 1895. In 1903 James L. Kraft established Kraft. General Foods merged with Kraft Inc. in
Under control: Fully automatic removal and stacking of intermediate layers and top covers by the vacuum suction system of the dl 71
kraFt FoodS IS an IntErnatIonal Food prodUcIng corporatIon wIth
ovEr 140,000 EMployEES and MarkEtS ItS prodUctS In MorE than 160 coUntrIES all ovEr thE world
Simply de icious
Kraft Foods is an international food producer and supplies customers in 160 countries.
More than 140,000 employees work to produce and market a large number of branded prod-ucts and place their emphasis on sustainable solutions that
protect the environment. Some of the most well-known brands from Kraft Foods include Côte
d’Or, MILKA, JACOBS, RITZ, TANG, OREO, PLANTERS,
MARABOU, LUNCHABLES, KENCO, PHILADELPHIA,
OSCAR MAYER, LU, TRIDENT, LACTA and
TASSIMO.
location in the Ukraine, the popular Western European coffee brand JACOBS can be sold in the entire Eastern European market. Prior to the prod-uct being directly packed in the Ukraine, serving these markets was accomplished through very expensive logistics. Three new machines from Meypack now make it much easier to have the valuable product readily available in the relatively large local market.
A pivotal reason for the purchase of the Mey-pack machines was the CleanDesign Construction Principle that was introduced and established for packaging machines, making them especially easy to clean. They are open and easily accessi-ble and therefore fast and easy to changeover and extremely easy to operate. In the meantime, CleanDesign is offered throughout the entire
area where Kraft Foods is active, utilising recycled materials.
a coMprEhEnSIvE packagIng SolUtIon For kraFt FoodS UkraIna
At one of its factories in the Ukraine, which is located in Trostyanets, Kraft Foods
decided to pack coffee directly in the Ukraine in order to pro-duce more quickly and create shorter transport routes. The
rationale for this large scale project was the continually rising sales of coffee products in the Eastern European developing market. The Ukrainian production facility in the vicinity of the Russian border was selected as an impor-tant link in the entire logistics chain. From the
Meypack packaging machine portfolio. Addi-tional supporting arguments for the purchase were the proven-in-practice technology, the solid design and the resulting long machine life and the high accessibility. Furthermore, Meypack was able to set itself apart from its competitors during bidding for the order due to its comprehensive line competence. Yet another plus point for the Meypack machines was the easy format change-overs. The operators can view all of the relevant setting parameters on the operator panel and can call up previously saved settings. The format changeover is thus not only fast but above all reproducible and error free.
thrEE nEw MEypack MachInES For kraFt FoodS
For the new packaging line, Meypack simulta-neously supplied a DL 71 depalletiser, a combined VP 520 SW 60 T tray/shrink wrapper as well as a PK 110 palletiser. The entire line processes octagonal jars filled with instant coffee (coffee granules) in 3 x 4 formations. The line primarily fills and packs 100 g jars but is designed to be able to accommodate jars filled with 50 g and 200 g of product.
At the beginning of the whole line, the empty jars are pushed layer for layer by a Meypack DL 71 depalletiser onto an intermediate table and then onto a buffer table. From there, the jars are transferred in rows onto the transport conveyors and fed into the production line. The second machine supplied by Meypack, a combined VP 520 SW 60 T tray/shrink wrapper, packs the jars filled with instant coffee into trays with film, after they have passed through the filling and
labelling machines. The jars are then grouped in the respective formats and positioned onto the tray blank. After that, the blank is folded around
precise: rotation and alignment of the cases at the infeed of the pk 110 in accordance to the defined layer pattern
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all in a row: distribution of the product flow into the individual lanes of the infeed on the vp 520 Sw 60 t
the product formation and then sealed. Next, the tray is packed in shrink film. Once the jars have been packed in trays with film, the trays are rotated and labelled. The shrink-wrapped and labelled trays are fed into the Meypack PK 110 palletiser and palletised according to a pre-defined layer pat-tern. The PK 110 palletiser is a high-capacity palletiser, has no format parts and all adjustments are carried out with a servo-motor.
B EWITAL petfood has been developing and producing high quality brand name, natural pet
food products, primarily for dogs, cats and ferrets since 1963. The focus of the company’s research is to develop healthy pet food recipes. These recipes are not only developed to reflect the fine example that nature provides, but they are produced in such a way that they are affordable for every bud-get, big or small. This strategy has proven itself over that past 47 years. Key factors in the success of this medium sized company have been the internal research and development, the resulting potential for innovation plus the production in Germany.
Among the most well-known brands on the pet food market are the premium brands BEL-CANDO®, LEONARDO®, BEWI DOG® and bewi cat®, while Fernando® and DOGLAND® serve the medium and low prices segments. In addition, the company also sells aniVital®, a supplement line for pet health problems.
pEt ownErShIp – a booMIng branch oF bUSInESS
Whether speaking of dogs as “man’s best friend” or about cats as “darling companions for life,” pet ownership is an unbroken trend, partic-ularly in Germany. According to the German Federation of Zoological Specialists, approximate-ly one in every three households had pets in 2009. Not counting ornamental fish or animals in terrar-iums, pets numbered 22.6 million, among those
5.4 million dogs, 8.2 million cats, 3.4 million birds and 5.6 million small animals.
Around 10,000 years ago, man began to keep animals from the wild for animal husbandry pur-poses. However, the practice of keeping pets also has a very long history, as people began domesti-cating animals for a variety of different personal reasons, including religious reasons, so that they could co-exist with people. Pet ownership is different from animal husbandry in that the animal kept does not serve any special economic purpose such as being a source of food, raw mate-rial supplier or protector against other animals. Today, pets are a meaningful social phenomenon and an enormous economic factor thanks to the sale of numerous products, especially in western societies.
hEalthy nUtrItIon – For hUManS and anIMalS
The growing trend in health conscious nutri-tion for humans can also be spurred in the pet food industry. People want to feed their pets the same level of high quality, healthy food that they choose for themselves. Subsequently, some pet foods are now being produced without any arti-ficial food colourings or preservatives. Further-more, special vitamin additives to support dental hygiene can be found today in many pet food products. BEWITAL petfood has recognized this trend and offers the right products to serve the wide range of customer wishes. For the products
in its “Quality Selection” line, BEWITAL petfood does not use any artificial colourings, preserva-tives, aromas or soy protein. Furthermore, only natural antioxidants and only genetically unmod-ified meat are used.
prIcE advantagE thankS to EconoMI-cal packagIng and EFFIcIEnt SEalIng tEchnology FroM MEypack
In order to also be able to offer products in medium and low price segments in addition to its premium products, the company has been using an efficiently operating Meypack CBS-W 600 continuous band sealer to close its bags of pet food since May 2010. The continuous motion technology of the CBS-W 600 provides extremely uniform sealing seams in any length. Thanks to the water cooling process, the seam can cool down while being clamped, which prevents it from distorting like it does when the more com-mon practice of air cooling is used. The machine for BEWITAL petfood is additionally equipped with a pair of serrated compression rollers that give the seams the appearance of the fashionable
“crimp-seal.” Another additional feature that the machine offers is a bag top trimmer that removes any bag material extending beyond the seam, ensuring a smooth edge – a requirement in the premium segment.
Meypack’s CBS-W 600 is the second bag closing machine in operation at BEWITAL petfood. The first machine, an FTS-B bag closing machine that closes paper bags, replaced an existing machine
from a competitor of Meypack’s in August 2008. The FTS closure made by the Meypack machine consists of a double fold that is secured against popping open by a sealing tape. This closure can be easily opened by the final consumer without using any tool, but instead a tear-off strip in the middle of the sealing tape.
The two machines are located one behind the other in the bagging line. This line can be used for both paper and plastic bags; changing over the type of bag can be carried out in a matter of minutes. In just two steps, BEWITAL petfood has turned an existing bagging line with very simple closing tech-nology into a high quality one.
For dEcadES, pEtS havE bEEn InhErEnt partS oF hoUSEholdS – In onE thIrd oF all hoMES today. and thE trEnd IS contInUIng. thE typIcal pEt ownEr SpEndS bEtwEEn 25 and 50 EUro pEr Month For ItS bElovEd coMpanIon. bEwItal pEtFood FroM Südlohn-oEdIng (nEar thE gErMan-dUtch bordEr) IS onE oF thE MoSt SUccESSFUl and InnovatIvE pEt Food prodUcErS In gErMany – and IS clEarly bEnEFItIng FroM thIS trEnd.
The nation’s darlings
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BEWITAL petfood from Südlohn-Oeding is one of the
most innovative pet food produ-cers in Germany. The company belongs to the BEWITAL group
of companies, which also pro-duces food for animal husbandry
needs. BEWITAL petfood has been developing and producing
high quality brand products for health conscious nutrition for pets since 1963, placing its trust in its internal research
and development as well as in production within Germany.
where precision and performance are mandatory: band sealing unit on Meypack’s cbS
22 kompackt 2/10
Colour coded system from Meypack
In ordEr to provIdE an ovErvIEw oF and clarIty aboUt thE nUMEroUS FacEtS oF MEypack’S MachInE prograMME, a coloUr codEd SyStEM waS dEvElopEd and thEn IntEgratEd Into thE nEw prodUct catalogUE
M eypack is a specialist for efficient, reliable and cus-tomised end-packaging
machines. The machines that Meypack designs, manufacturers and maintains are used for a wide variety of applications, which Meypack has group-ed into different machine series. These include the VP Series for case packers, the SW Series for shrink wrappers, the FW Series for stretch-film wrappers, the DL Series for depalletisers and the PK Series for palletisers. In addition to the end-packaging machines, Meypack also has the SVT Series for its bag closing machines.
To ease both internal and external communica-tion, Meypack produced a new product catalogue incorporating a newly developed colour coded system in 2008. This helps provide an overview of and clarity about the numerous facets of Meypack’s machine programme. It is based on a simple principle: each of the six colour accents represents a series. What’s unique about this is that the concept has now been applied to all of the communication and will become a fundamental component of Meypack’s corporate design in the future.
coloUr codEd SyStEM – a dIrEctory throUgh SyStEMS
Colour coded systems have their origins in the world of architecture and are based on the idea that functional aspects can be summarised under colour schemes. For example, during the Weimar Bauhaus period, stairwells and entrance
ways were equipped with colour coded direction systems that allowed the occupants and their visitors to find their ways on their own. Today, such so-called signal orientation systems can be applied to many different areas, such as web-sites, manuals or catalogues. As such, a colour coded system is an instrument of universal communication.
paStEl tonES not In coMpEtItIon wIth MEypack’S coMpany coloUrS
The pastel colours selected for Meypack’s colour coded system were chosen for a reason. During development, it was of the utmost importance that these should in no way “compete” for attention with Meypack’s company colours (blue, white, grey). As a result, these pastel accent colours take a back seat and serve to complement the company colours.
In addition to appearing on the company letter-head and functioning as design element of trade fair stands, the respective colours will be used in presentations and films as well as in the colour strips in the machine photos on the product infor-mation sheets, mailings and in the “kompackt” customer magazine. The objective of this is for the observer to receive visual stimulus highlighting which machine series is being shown in a film or explained in a presentation. As recurring elements, the colours symbolise the whole world of the Mey-pack machine series.
Colours in series. Series in colour.
The FachPack is back – from Septem-ber 28th to 30th, 2010. At Meypack’s Stand 3-323 in Hall 3 at the FachPack 2010 in Nuremberg, Meypack will be presenting its specially designed solution to pack pouches sealed on 4 sides and Doypacks into display trays with lids applied to the outside of the tray. To secure the lid, its long side is partially inserted into the tray and adhesive is additionally applied. The Meypack VP 453 on display is capable of processing different product formations – depending upon the respective pouch size. It can pack both single chamber as well as double chamber pouches. The machine will be on display “in action” at Meypack’s trade fair stand.
MEypack prESEntS InnovatIvE cUStoM-ISEd SolUtIon at thE Fachpack 2010 In nUrEMbErg
Fall fairs 2010
DATES
SEptEMbEr 28th to 30th, 2010Fachpack, nuremberg, germany
novEMbEr 10th to 12th, 2010braU beviale, nuremberg, germany
May 12th to 18th, 2011interpack, düsseldorf, germany
oFF to nEw ShorES: thorStEn dabEck takES ovEr SparE partS bUSInESS
Thorsten Dabeck, who has been back working in Meypack’s Customer Service Department since the beginning of Novem-ber 2008, took over the reins of the spare parts business for shrink wrappers and bag closing machines from Simon Brüsch in mid-June 2010. Mr Brüsch, who came to Appelhülsen after the production facility in Schenefeld (near Hamburg) was relocated there, left Meypack to pursue his studies. Thorsten Dabeck had completed an apprenticeship at Meypack before he joined the Custom-er Service Department in Nottuln-Appelhülsen. He also served in the Customer Service Department in Schenefeld. Mr Dabeck thus brings solid expertise and experience in the spare parts business to his new position.
oxana kSEndSUk joInS MEypack’S SErvIcE tEaM
The former position held by Thorsten Dabeck in Custom-er Service was filled by Oxana Ksendsuk in July 2010. Mr Dabeck showed Ms Ksendsuk the ropes of her new position during her traineeship. Oxana Ksendsuk is a valuable addi-tion to Meypack’s Customer Service Team, particularly for the international business thanks to her strong linguistic abilities. She speaks Ukrai-nian, Russian, German and English fluently. Ms Ksendsuk will support Custom-er Service Manager Ludger Reismann in planning and organising the service technicians, shipping spare and machine parts as well as in invoicing matters. She is often the first person of contact in the Customer Service Department for Meypack’s customers.
oxana ksendsuk
thorsten dabeck
welcomed to exchange ideas and discuss concrete projects for 2011 in a relaxing and comfortable atmosphere.. With over 1,400 exhibitors and around 35,000 expected visitors, the Brau Beviale is one of the most important trade fairs for the European beverage industry.
On the heels of the FachPack, the Brau Beviale 2010 will also be opening its doors in Nuremberg. This big get-together of the beverage and brewing industries will take place from November 10th to 12th, 2010. Meypack will be in Hall 7 at Stand 7-334/336 with its well-received lounge, where many German and international customers and interested parties will be
Last butnot least
PERSONNEL
Meypack verpackungssystemtechnik gmbh Industriestraße 3 · d-48301 nottuln-appelhülsen · tel.: +49 (0) 2509 - 940 · Fax: +49 (0) 2509 - 948190 · [email protected]
www.meypack.de
